Service Training

MALAGA

992G WHEEL LOADER

5. IMPLEMENT SYSTEM
1. Components Layout
2. Operation
3. Testing & Adjusting

Adolfo
OCTOBER 1997
Page:

ELECTRO-HYDRAULIC IMPLEMENT SYSTEM

5-2

VARIABLE PUMP PILOT ELECTRONIC PILOT CONTROL

SOLENOID VALVE RELIEF CONTROL LEVER MODULE
VALVE MODULE
IMPLEMENT PILOT MAIN CONTROL TILT
HYDRAULIC PUMP VALVE ASSEMBLY CYLINDER
PUMPS

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

HYDRAULIC LIFT LINKAGE LIFT TILT LINKAGE
TANK POSITION SENSOR CYLINDER POSITION SENSOR

ELECTRONIC SYSTEM MAIN HYDRAULIC SYSTEM

HYDRAULIC PILOT SYSTEM COMMON TO BOTH SYSTEMS
Page:

ELECTRONIC IMPLEMENT CONTROL SYSTEM

5-3

IMPLEMENT ELECTRONIC
CONTROL MODULE
(MAC-14)

CAT
DATA LINK
INPUT COMPONENTS OUTPUT COMPONENTS

PILOT ON/OFF
TILT LEVER SOLENOID
SENSOR
VARIABLE PUMP
SOLENOID
LIFT LEVER
SENSOR
TILT RACKBACK
SOLENOID NO. 1

IMPLEMENT TILT RACKBACK

LOCKOUT SWITCH SOLENOID NO. 2

CHAPTER : IMPLEMENT SYSTEM

TILT DUMP
LIFT/LOWER/TILT SOLENOID NO. 1
KICKOUT SWITCH
TILT DUMP

992G WHEEL LOADER

SOLENOID NO. 2
LIFT LINKAGE
SENSOR LIFT LOWER
SOLENOID NO. 1

TILT LINKAGE LIFT LOWER

SENSOR SOLENOID NO. 2

LIFT RAISE
SOLENOID NO. 1

LIFT RAISE
SOLENOID NO. 2

LIFT LOWER KICKOUT

DETENT SOLENOID

LIFT RAISE KICKOUT

DETENT SOLENOID

BUCKET KICKOUT
DETENT SOLENOID
Page:
5-4

ELECTRO-HYDRAULIC
IMPLEMENT SYSTEM
TILT
PILOT SYSTEM COMPONENTS RIGHT
CYLINDER
LEFT
LIFT LIFT
CYLINDER CYLINDER

SHUTTLE
VALVE

IMPLEMENT RAISE/LOW/TILT
LOCKOUT KICKOUT SET
SWITCH SWITCH PRESSURE
REDUCING
VALVE

CHAPTER : IMPLEMENT SYSTEM

TILT LINKAGE
POSITION SENSOR
IMPLEMENT IMPLEMENT
CONTROL CONTROL
VALVE VALVE

992G WHEEL LOADER

ELECTRONIC
CAT CONTROL CHECK
DATA MODULE LIFT LINKAGE VALVE
LINK POSITION SENSOR PILOT
ON/OFF
VALVE

CHECK
BUCKET LIFT LOWER VALVE
KICKOUT KICKOUT KICKOUT
DETENT DETENT DETENT
SOLENOID SOLENOID RELIEF
SOLENOID VALVE
RELIEF PILOT FILTER
TILT LIFT VALVE RELIEF
LEVER LEVER VALVE
SENSOR SENSOR VARIABLE
PUMP
SOLENOID VARIABLE
FIXED PILOT VALVE PUMP
PUMP PUMP
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

COMPONENTS

SERVICE TOOL CONNECTOR FILL CAP

VENT VALVE HYDRAULIC TANK

Page: 5-5
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

PILOT SYSTEM COMPONENTS

PILOT PUMP IMPLEMENT VARIABLE

PISTON PUMP

PUMP OUTLET PILOT CIRCUIT

PRESSURE TAP

Page: 5-6
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

PILOT CIRCUIT COMPONENTS

OIL FILTER BYPASS SWITCH HYDRAULIC OIL FILTER

OIL OUTLET OIL INLET

Page: 5-7
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

PILOT CIRCUIT COMPONENTS

PILOT RELIEF VALVE SIGNAL LINE

PILOT RELIEF VALVE VARIABLE PUMP

PRESSURE SENSOR SOLENOID VALVE

Page: 5-8
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

MAIN CONTROL VALVES

TILT ROD END LINE TILT HEAD END LINE

FIXED PUMP
RELIEF VALVE RELIEF VALVE
RELIEF VALVE

LIFT HEAD END

PILOT CONTROL PILOT ON/OFF LINE RELIEF VALVE
SOLENOID VALVES SOLENOID VALVE

LIFT ROD END FLOAT

LINE RELIEF FLOAT SEQUENCE
VALVE VALVE VALVE

Page: 5-9
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

IMPLEMENT PUMPS

VARIABLE PUMP

CASE DRAIN
FIXED PUMP

Page: 5-10
Page:
5-11

ELECTRO-HYDRAULIC
IMPLEMENT SYSTEM
TILT
MAIN HYDRAULIC SYSTEM COMPONENTS RIGHT
CYLINDER
LEFT
LIFT LIFT
CYLINDER CYLINDER

SHUTTLE
VALVE

IMPLEMENT RAISE/LOW/TILT
LOCKOUT KICKOUT SET
SWITCH SWITCH PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR

CHAPTER : IMPLEMENT SYSTEM

IMPLEMENT IMPLEMENT
CONTROL CONTROL
VALVE VALVE

992G WHEEL LOADER

ELECTRONIC
CAT CONTROL CHECK
DATA MODULE LIFT LINKAGE VALVE
LINK POSITION SENSOR PILOT
ON/OFF
VALVE

CHECK
BUCKET LIFT LOWER VALVE
KICKOUT KICKOUT KICKOUT
DETENT DETENT DETENT
SOLENOID SOLENOID RELIEF
SOLENOID VALVE
RELIEF PILOT
RELIEF FILTER
TILT LIFT VALVE
LEVER LEVER VALVE
SENSOR SENSOR VARIABLE
PUMP
SOLENOID VARIABLE
FIXED PILOT VALVE
PUMP PUMP
PUMP
Page:

VARIABLE PUMP
5-12

SOLENOID VALVE
TO PILOT
SYSTEM
VARIABLE IMPLEMENT PUMP
LESS THAN 2400kPa (350 psi)

TO TANK
PILOT TO IMPLEMENT
RELIEF CONTROL VALVE
VALVE
PRESSURE

CHAPTER : IMPLEMENT SYSTEM

CUTOFF

LOAD
PILOT

992G WHEEL LOADER

LIMIT SHUTTLE
FILTER CONTROL VALVE

FLUID
SAMPLING
PORT SMALL
ACTUATOR
PILOT
PUMP PUMP
LARGE
ACTUATOR
Page:

VARIABLE PUMP
SOLENOID VALVE
TO PILOT
5-13

SYSTEM

VARIABLE IMPLEMENT PUMP

LESS THAN 24,500 kPa (3550 psi)

TO TANK
PILOT TO IMPLEMENT
RELIEF CONTROL VALVE
VALVE
PRESSURE
CUTOFF

CHAPTER : IMPLEMENT SYSTEM

LOAD
PILOT LIMIT SHUTTLE

992G WHEEL LOADER

FILTER CONTROL VALVE

FLUID
SAMPLING
PORT SMALL
ACTUATOR
PILOT
PUMP
LARGE PUMP
ACTUATOR
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

VARIABLE PUMP
SOLENOID VALVE

IMPLEMENT
PILOT RELIEF

VARIABLE PUMP SOLENOID VALVE

CONTROLS PILOT PRESSURE TO LOAD LIMITING CONTROL VALVE ON
VARIABLE PUMP CONTROL

ECM ENERGIZES SOLENOID WHEN KEY SWITCH ON

RECEIVES CONSTANT SIGNAL FROM ECM

SUPPLIES PILOT OIL TO LOAD LIMIT CONTROL

MAINTAINS 80% PUMP FLOW (27600<P<28900 kPa)

Page: 5-14
Page:

VARIABLE PUMP
SOLENOID VALVE
5-15

TO PILOT
SYSTEM
VARIABLE IMPLEMENT PUMP
MORE THAN 28,940 kPa (4200 psi)

TO TANK
PILOT TO IMPLEMENT
RELIEF CONTROL VALVE
VALVE
PRESSURE

CHAPTER : IMPLEMENT SYSTEM

CUTOFF

LOAD
PILOT

992G WHEEL LOADER

LIMIT SHUTTLE
FILTER CONTROL VALVE

FLUID
SAMPLING
PORT SMALL
ACTUATOR
PILOT
PUMP PUMP
LARGE
ACTUATOR
Page:
5-16

ELECTRO-HYDRAULIC TILT
CYLINDER
IMPLEMENT SYSTEM RIGHT
LIFT
LEFT
LIFT
CYLINDER CYLINDER
HOLD
SHUTTLE
VALVE

IMPLEMENT RAISE/LOW/TILT
LOCKOUT KICKOUT SET
SWITCH SWITCH PRESSURE
REDUCING
VALVE

CHAPTER : IMPLEMENT SYSTEM

TILT LINKAGE
POSITION SENSOR
IMPLEMENT IMPLEMENT
CONTROL CONTROL
VALVE VALVE

992G WHEEL LOADER

ELECTRONIC
CAT CONTROL CHECK
DATA MODULE LIFT LINKAGE VALVE
LINK POSITION SENSOR PILOT
ON/OFF
VALVE

CHECK
BUCKET LIFT LOWER VALVE
KICKOUT KICKOUT KICKOUT
DETENT DETENT DETENT
SOLENOID SOLENOID RELIEF
SOLENOID PILOT VALVE
RELIEF RELIEF
TILT LIFT FIXED VALVE VALVE FILTER
LEVER LEVER PUMP
SENSOR SENSOR VARIABLE
PUMP
SOLENOID VARIABLE
PILOT VALVE PUMP
PUMP
Page:
5-17

ELECTRO-HYDRAULIC TILT
CYLINDER
IMPLEMENT SYSTEM RIGHT
LIFT
LEFT
LIFT
CYLINDER CYLINDER
SLOW TILT
SHUTTLE
VALVE

IMPLEMENT RAISE/LOW/TILT
LOCKOUT KICKOUT SET
SWITCH SWITCH PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR

CHAPTER : IMPLEMENT SYSTEM

IMPLEMENT IMPLEMENT
CONTROL CONTROL
VALVE VALVE

992G WHEEL LOADER

ELECTRONIC
CAT CONTROL CHECK
DATA MODULE LIFT LINKAGE VALVE
LINK POSITION SENSOR PILOT
ON/OFF
VALVE

CHECK
BUCKET LIFT LOWER VALVE
KICKOUT KICKOUT KICKOUT
DETENT DETENT DETENT
SOLENOID SOLENOID RELIEF
SOLENOID PILOT VALVE
RELIEF RELIEF
TILT LIFT FIXED VALVE VALVE FILTER
LEVER LEVER PUMP
SENSOR SENSOR VARIABLE
PUMP
SOLENOID VARIABLE
PILOT VALVE PUMP
PUMP
Page:
5-18

ELECTRO-HYDRAULIC TILT
CYLINDER
IMPLEMENT SYSTEM RIGHT
LIFT
LEFT
LIFT
CYLINDER CYLINDER
FAST TILT
SHUTTLE
VALVE

IMPLEMENT RAISE/LOW/TILT
LOCKOUT KICKOUT SET
SWITCH SWITCH PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR

CHAPTER : IMPLEMENT SYSTEM

IMPLEMENT IMPLEMENT
CONTROL CONTROL
VALVE VALVE

992G WHEEL LOADER

ELECTRONIC
CAT CONTROL CHECK
DATA MODULE LIFT LINKAGE VALVE
LINK POSITION SENSOR PILOT
ON/OFF
VALVE

CHECK
BUCKET LIFT LOWER VALVE
KICKOUT KICKOUT
DETENT KICKOUT
DETENT DETENT
SOLENOID SOLENOID RELIEF
SOLENOID PILOT VALVE
RELIEF RELIEF
TILT LIFT FIXED VALVE VALVE FILTER
LEVER LEVER PUMP
SENSOR SENSOR VARIABLE
PUMP
SOLENOID VARIABLE
PILOT VALVE PUMP
PUMP
Page:
5-19

ELECTRO-HYDRAULIC TILT
CYLINDER
IMPLEMENT SYSTEM RIGHT
LIFT
LEFT
LIFT
CYLINDER CYLINDER
SLOW LIFT
SHUTTLE
VALVE

IMPLEMENT RAISE/LOW/TILT
LOCKOUT KICKOUT SET
SWITCH SWITCH PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
IMPLEMENT IMPLEMENT

CHAPTER : IMPLEMENT SYSTEM

CONTROL CONTROL
VALVE VALVE

992G WHEEL LOADER

ELECTRONIC
CAT CONTROL CHECK
DATA MODULE LIFT LINKAGE VALVE
LINK POSITION SENSOR PILOT
ON/OFF
VALVE

CHECK
BUCKET LIFT LOWER VALVE
KICKOUT KICKOUT KICKOUT
DETENT DETENT
SOLENOID DETENT RELIEF
SOLENOID SOLENOID PILOT VALVE
RELIEF RELIEF
TILT LIFT FIXED VALVE VALVE FILTER
LEVER LEVER PUMP
SENSOR SENSOR VARIABLE
PUMP
SOLENOID VARIABLE
PILOT VALVE PUMP
PUMP
Page:
5-20

ELECTRO-HYDRAULIC
IMPLEMENT SYSTEM TILT
RIGHT CYLINDER
LEFT
FAST LIFT LIFT LIFT
CYLINDER CYLINDER

SHUTTLE
VALVE

IMPLEMENT RAISE/LOW/TILT
LOCKOUT KICKOUT SET
SWITCH SWITCH PRESSURE
REDUCING
VALVE
TILT LINKAGE
POSITION SENSOR
IMPLEMENT IMPLEMENT

CHAPTER : IMPLEMENT SYSTEM

CONTROL CONTROL
VALVE VALVE

992G WHEEL LOADER

ELECTRONIC
CAT CONTROL CHECK
DATA MODULE LIFT LINKAGE VALVE
LINK POSITION SENSOR PILOT
ON/OFF
VALVE

CHECK
BUCKET LOWER VALVE
KICKOUT LIFT
DETENT KICKOUT KICKOUT
SOLENOID DETENT DETENT RELIEF
SOLENOID SOLENOID PILOT VALVE
RELIEF RELIEF
TILT LIFT FIXED VALVE VALVE FILTER
LEVER LEVER PUMP
SENSOR SENSOR VARIABLE
PUMP
SOLENOID VARIABLE
PILOT VALVE PUMP
PUMP
Page:

IMPLEMENT HYDRAULIC SYSTEM

HOLD LIFT LIFT
5-21

TILT CYLINDER CYLINDER

CYLINDER

PRESSURE
REDUCING
VALVE SHUTTLE
VALVE

LOWER TILT TILT LOWER RIDE

CONTROL

PILOT
ON/OFF
VALVE

FLOAT FLOAT
SEQUENCE VALVE
VARIABLE PUMP VALVE FLOAT
SOLENOID VALVE VALVE

CHAPTER : IMPLEMENT SYSTEM

RAISE DUMP DUMP RAISE

992G WHEEL LOADER

PILOT FAN
RELIEF MOTOR
VALVE FAN SPEED
PRESSURE
CUTOFF
COOLER
SHUTTLE
VALVE FIXED
PUMP

LOAD LIMIT
CONTROL FAN
FLUID DRIVE
SAMPLING SMALL PUMP
PORT ACTUATOR
VARIABLE
LARGE PUMP
ACTUATOR
PILOT
PUMP
Page:

IMPLEMENT HYDRAULIC SYSTEM

SLOW TILT
5-22

LIFT LIFT
TILT CYLINDER CYLINDER
CYLINDER

PRESSURE
REDUCING
VALVE SHUTTLE
VALVE

LOWER TILT TILT LOWER RIDE

CONTROL

PILOT
ON/OFF
VALVE

FLOAT FLOAT
SEQUENCE VALVE
VARIABLE PUMP VALVE FLOAT

CHAPTER : IMPLEMENT SYSTEM

SOLENOID VALVE VALVE
RAISE DUMP DUMP RAISE

992G WHEEL LOADER

PILOT FAN
RELIEF MOTOR
VALVE FAN SPEED
PRESSURE
CUTOFF
COOLER
SHUTTLE
VALVE FIXED
PUMP

LOAD LIMIT FAN

FLUID CONTROL
SAMPLING DRIVE
PORT SMALL PUMP
ACTUATOR
VARIABLE
LARGE PUMP
ACTUATOR
PILOT
PUMP
Page:
5-23

IMPLEMENT HYDRAULIC SYSTEM

FAST TILT LIFT LIFT
TILT CYLINDER CYLINDER
CYLINDER

PRESSURE
REDUCING SHUTTLE
VALVE VALVE

LOWER TILT TILT LOWER RIDE

CONTROL

PILOT
ON/OFF
VALVE

FLOAT FLOAT
SEQUENCE VALVE
VARIABLE PUMP VALVE FLOAT

CHAPTER : IMPLEMENT SYSTEM

SOLENOID VALVE VALVE
RAISE DUMP DUMP RAISE

992G WHEEL LOADER

PILOT FAN
RELIEF MOTOR
VALVE FAN SPEED
PRESSURE
CUTOFF
COOLER
SHUTTLE
VALVE FIXED
PUMP

LOAD LIMIT FAN

FLUID CONTROL DRIVE
SAMPLING PUMP
PORT SMALL
ACTUATOR
VARIABLE
LARGE PUMP
ACTUATOR
PILOT
PUMP
Page:

IMPLEMENT HYDRAULIC SYSTEM

SLOW LOWER
5-24

LIFT LIFT
TILT CYLINDER CYLINDER
CYLINDER

PRESSURE
REDUCING
SHUTTLE
VALVE VALVE

LOWER TILT TILT LOWER RIDE

CONTROL

PILOT
ON/OFF
VALVE

FLOAT FLOAT
SEQUENCE VALVE
VALVE FLOAT
VARIABLE PUMP
SOLENOID VALVE VALVE

CHAPTER : IMPLEMENT SYSTEM

RAISE DUMP DUMP RAISE

992G WHEEL LOADER

PILOT FAN
RELIEF MOTOR
VALVE FAN SPEED
PRESSURE
CUTOFF
COOLER
SHUTTLE
VALVE FIXED
PUMP

LOAD LIMIT
CONTROL FAN
FLUID DRIVE
SAMPLING SMALL PUMP
PORT ACTUATOR
VARIABLE
LARGE PUMP
ACTUATOR
PILOT
PUMP
Page:

IMPLEMENT HYDRAULIC SYSTEM

5-25

FAST LOWER LIFT LIFT

TILT CYLINDER CYLINDER
CYLINDER

PRESSURE
REDUCING
SHUTTLE
VALVE VALVE

LOWER TILT TILT LOWER RIDE

CONTROL

PILOT
ON/OFF
VALVE

FLOAT FLOAT
SEQUENCE VALVE
VARIABLE PUMP VALVE FLOAT

CHAPTER : IMPLEMENT SYSTEM

SOLENOID VALVE VALVE
RAISE DUMP DUMP RAISE

992G WHEEL LOADER

PILOT FAN
RELIEF MOTOR
VALVE FAN SPEED
PRESSURE
CUTOFF
COOLER
SHUTTLE
VALVE FIXED
PUMP

FLUID LOAD LIMIT FAN

SAMPLING CONTROL DRIVE
PORT PUMP
SMALL
ACTUATOR
LARGE VARIABLE
ACTUATOR PUMP

PILOT
PUMP
Page:

IMPLEMENT HYDRAULIC SYSTEM

FLOAT LIFT LIFT
5-26

TILT CYLINDER CYLINDER

CYLINDER

PRESSURE
REDUCING
SHUTTLE
VALVE VALVE

LOWER TILT TILT LOWER RIDE

CONTROL

PILOT
ON/OFF
VALVE

FLOAT FLOAT
SEQUENCE VALVE
VARIABLE PUMP VALVE FLOAT
SOLENOID VALVE VALVE

CHAPTER : IMPLEMENT SYSTEM

RAISE DUMP DUMP RAISE

992G WHEEL LOADER

PILOT FAN
RELIEF MOTOR
VALVE FAN SPEED
PRESSURE
CUTOFF
COOLER
SHUTTLE
VALVE FIXED
PUMP

LOAD LIMIT FAN

FLUID CONTROL
SAMPLING DRIVE
PORT PUMP
SMALL
ACTUATOR
LARGE VARIABLE
ACTUATOR PUMP

PILOT
PUMP
Page:
5-27

FLOAT VALVE

PLUG
PASSAGE TO
SEQUENCE VALVE

CHAPTER : IMPLEMENT SYSTEM

992G WHEEL LOADER

TO LIFT CYLINDER
ROD END

ORIFICE
FLOAT OFF FLOAT ON
Page:

IMPLEMENT HYDRAULIC SYSTEM

LOWER ENGINE OFF LIFT
5-28

LIFT TILT CYLINDER

CYLINDER CYLINDER

PRESSURE
REDUCING
SHUTTLE
VALVE VALVE

LOWER TILT TILT LOWER RIDE

CONTROL

PILOT
ON/OFF
VALVE

FLOAT FLOAT
SEQUENCE VALVE
VARIABLE PUMP VALVE FLOAT
SOLENOID VALVE VALVE

CHAPTER : IMPLEMENT SYSTEM

RAISE DUMP DUMP RAISE

992G WHEEL LOADER

PILOT FAN
RELIEF MOTOR
VALVE FAN SPEED

PRESSURE
CUTOFF COOLER
SHUTTLE
VALVE FIXED
PUMP

FLUID LOAD LIMIT FAN

SAMPLING CONTROL DRIVE
PORT PUMP
SMALL
ACTUATOR
LARGE VARIABLE
ACTUATOR PUMP

PILOT
PUMP
Page:

IMPLEMENT HYDRAULIC SYSTEM

5-29

RIDE CONTROL ON LIFT LIFT

TILT CYLINDER CYLINDER
CYLINDER

PRESSURE
REDUCING
SHUTTLE
VALVE VALVE

LOWER TILT TILT LOWER RIDE

CONTROL

PILOT
ON/OFF
VALVE

FLOAT FLOAT
SEQUENCE VALVE
VARIABLE PUMP VALVE FLOAT

CHAPTER : IMPLEMENT SYSTEM

SOLENOID VALVE VALVE
RAISE DUMP DUMP RAISE

992G WHEEL LOADER

PILOT FAN
RELIEF MOTOR
VALVE FAN SPEED
PRESSURE
CUTOFF
COOLER
SHUTTLE
VALVE FIXED
PUMP

FLUID LOAD LIMIT FAN

SAMPLING CONTROL DRIVE
PORT PUMP
SMALL
ACTUATOR
LARGE VARIABLE
ACTUATOR PUMP

PILOT
PUMP
Page:
5-30

FAN DRIVE SYSTEM

ENGINE OFF
FAN
ENGINE
ECM FAN
MOTOR

SCREEN

MAKEUP
VALVE

PROPORTIONAL

CHAPTER : IMPLEMENT SYSTEM

FAN
DRIVE VALVE
PUMP OIL

992G WHEEL LOADER

COMPENSATOR COOLER
VALVE IMPLEMENT BYPASS
HYDRAULIC VALVE
COOLER

TANK INPUTS TO PROPORTIONAL VALVE:

--COOLANT TEMPERATURE SENSOR
--STEERING TANK TEMPERATURE SENSOR
--IMPLEMENT TANK TEMPERATURE SENSOR
--AIR CONDITIONER ON/OFF SWITCH
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

FAN DRIVE COMPONENTS

SYSTEM FAN DRIVE SIGNAL PROPORTIONAL

PRESSURE PUMP PRESSURE VALVE
TEST PORT OUTLET SOLENOID

MARGIN SPOOL COMPENSATOR SIGNAL

ADJUSTMENT VALVE PRESSURE TEST
PORT
PRESSURE
ELECTRO-HYDRAULIC
COMPENSATOR
PROPORTIONAL VALVE
ADJUSTMENT

Page: 5-31
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

INTAKE HOSE OUTLET HOSE

CASE DRAIN
FAN DRIVE HOSE
MOTOR

Page: 5-32
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

992G COOLER LOCATION

ENGINE

Page: 5-33
Page:
5-34

FAN DRIVE SYSTEM FAN

SOLENOID DE-ENERGIZED FAN
PUMP UPSTROKES MOTOR

SCREEN

MAKEUP
VALVE

CHAPTER : IMPLEMENT SYSTEM

FAN PROPORTIONAL
DRIVE VALVE
PUMP OIL

992G WHEEL LOADER

COMPENSATOR COOLER
VALVE IMPLEMENT BYPASS
HYDRAULIC VALVE
COOLER

TANK
Page:
5-35

FAN DRIVE SYSTEM FAN

SOLENOID ENERGIZED FAN
MOTOR

SCREEN

MAKEUP
VALVE

CHAPTER : IMPLEMENT SYSTEM

FAN PROPORTIONAL
DRIVE VALVE
PUMP OIL

992G WHEEL LOADER

COMPENSATOR COOLER
VALVE IMPLEMENT BYPASS
HYDRAULIC VALVE
COOLER

TANK
Page:
5-36

FAN DRIVE SYSTEM FAN

RAPID ENGINE DECELERATION FAN
MOTOR

SCREEN

MAKEUP
VALVE

CHAPTER : IMPLEMENT SYSTEM

FAN PROPORTIONAL
DRIVE VALVE
PUMP OIL

992G WHEEL LOADER

COMPENSATOR COOLER
VALVE IMPLEMENT BYPASS
HYDRAULIC VALVE
COOLER

TANK
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

6
5 7

1
3

8
4

1- HYDRAULIC CONTROL LEVERS

2- TILT LEVER POSITION SENSOR

3- HORN

4- RIGHT ARMREST CONTROL LEVER

5- REDUCED RIMPULL SWITCH

6- THROTTLE LOCK SET SWITCH

7- IMPLEMENT HYDRAULIC LOCK SWITCH

8- CONTROL LEVER COVER

- DETENT SOLENOIDS (UNDER COVER)

Page: 5-37
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

SETTING BUCKET KICKOUTS

TO SET KICK-OUTS PRESS & HOLD UPPER, LOWER OR TILT

KICK-OUTS FOR APROXIMATELY ONE SECOND

UPPER KICK-OUT
(above mid point)

X/2 GOES TO KICK-OUT

GOES TO FLOAT
X (hits ground)

LOWER KICK-OUT

Page: 5-38
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

LINKAGE POSITION SENSOR REPLACE

1- REPLACE AND INSTALL SENSOR AS INDICATED IN T&A
2- DIAL “SERV” IN KEYPAD
3- SCROLL (>) TO SET SENSORS, LIFT SENSORS ONLY
4- FOLLOW INSTRUCTION UNTIL TARGET NUMBER APPEARS (%)
5- OK WILL SHUTOFF ENGINE (LEAVE KEY SWITCH ON)
6- ADJUST SENSOR ROTATING SHAFT WITH ROLLER IN CENTRE OF CAM
7 - DUTY CYCLE CAN BE READ ON DISPLAY OR CONNECTING FLUKE TO SENSOR
8- PERFORM CALIBRATION BEFORE PUTTING MACHINE BACK IN SERVICE
LINKAGE POSITION SENSOR CALIBRATION
1- PARKING BRAKE ON
2- RIDE CONTROL SWITCH OFF
3- LOW IDLE
4- HYD OIL TEMP > 30 C
5- PRESS OK UNTIL ALL EVENTS ACKNOWLEDGED
6- ENTER SERV
7- PRESS SCROLL (>) UNTIL LFT LINK SNSR - CAL
8- FOLLOW INSTRUCTIONS
Page: 5-39
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

IMPLEMENT VALVE CALIBRATION

CALIBRATES EIGHT PROPORTIONAL SOLENOIDS

PERFORM IF FOLLOWING CONDITIONS APPLY:

- ONE OR MORE SOLENOIDS REPLACED

- SERVICE CODE INDICATES CALIBRATION NEEDED

- IMPLEMENT ELECTRONIC MODULE REPLACED

PROCEDURE
1) PKNG BRAKE ON
2) LOW IDLE
3) MACHINE IN WIDE OPEN SPACE
4) HYDRAULIC OIL > 30°C
5) “OK” UNTIL ALL EVENTS ACKNOWLEDGED
6) “SERV” AND SCROLL (>) UNTIL
“IMPL VALVE SOL - CAL” APPEARS
7) “OK” TO START.....FOLLOW INSTRUCTIONS
ERRORS
1 - SOLENOID ERROR CHECK FOR CODES, CORRECT AND
CHECK SOL/CAL/WIRNG RECALIBRATE

2 - CURRENT ABOVE RANGE HYDRAULIC PROBLEMS. CHECK

IMPLEMENT AND PILOT PUMP
PRESSURES. MAKE SURE BUCKET IS

3- CURRENT BELOW RANGE HYDRAULIC PROBLEMS. CHECK

FOR EXCESSIVE CYLINDER DRIFT
4 - LFT LINK SNSR ERR CHECK FOR CODES, CORRECT AND
CHECK SNSR/CAL/WIRNG RECALIBRATE

Page: 5-40
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

VARIABLE DISPLACEMENT PUMP TESTS

DISSABLES LEFT SIDE OF IMPLEMENT CONTROL VALVE

ISOLATES VARIABLE DISPLACEMENT PUMP

PROCEDURE
1) PKNG BRAKE ON
2) XMS NEUTRAL
3) START ENGINE
4) WARM OIL TO 49°C
5) “OK” UNTIL ALL EVENTS ACKNOWLEDGED
6) “SERV” AND SCROLL (>) UNTIL
“IMPL RLF - VAR PUMP” APPEARS
7) “OK” TO START.....FOLLOW INSTRUCTIONS
8) EVERY 5 SEC
PRESS [<] OR [>]
TO SEE SPEC LIST
SPECIFICATIONS INDICATED ON MESSAGE DISPLAY ARE
UPDATED THROUGH SOFTWARE FILES.
COULD BE DIFFERENT TO SPECS IN SERVICE MANUAL.
SPECS LISTED:
- VARIABLE DISPLACEMENT PUMP CUTOFF
- RIGHT VALVE DUMP LINE RELIEF PRESSURE
- BUCKET LIFT TIME WITH VARIABLE PUMP ONLY
- DOUBLE STALL RPM WITH VARIABLE PUMP ONLY
- RIGHT VALVE BACK UP RELIEF SETTING

Page: 5-41
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

FIXED DISPLACEMENT PUMP TESTS

DISSABLES RIGHT SIDE OF IMPLEMENT CONTROL VALVE

ISOLATES FIXED DISPLACEMENT PUMP

PROCEDURE
1) PKNG BRAKE ON
2) XMS NEUTRAL
3) START ENGINE
4) WARM OIL TO 49°C
5) “OK” UNTIL ALL EVENTS ACKNOWLEDGED
6) “SERV” AND SCROLL (>) UNTIL
IMPL RLF - FIX PUMP APPEARS
7) “OK” TO START.....FOLLOW INSTRUCTIONS
8) EVERY 5 SEC
PRESS [<] OR [>]
TO SEE SPEC LIST
SPECIFICATIONS INDICATED ON MESSAGE DISPLAY ARE
UPDATED THROUGH SOFTWARE FILES.
COULD BE DIFFERENT TO SPECS IN SERVICE MANUAL.
SPECS LISTED:
- FIXED DISPLACEMENT PUMP MAIN RELIEF
- LEFT VALVE DUMP LINE RELIEF PRESSURE
- BUCKET LIFT TIME WITH FIXED PUMP ONLY
- DOUBLE STALL RPM WITH FIXED PUMP ONLY
- LEFT VALVE TILT LINE RELIEF SETTING
- LEFT VALVE LOWER LINE RELIEF SETTING
- LEFT VALVE RAISE LINE RELIEF SETTING

Page: 5-42
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

LAB EXERCISES
Lab A: Implement Hydraulic Component Identification Quiz
Worksheet

Directions: Use this worksheet and the notes during the presentation to locate the components on the
machine.

Component Location on the Machine

Pilot pump

Fan drive pump

Pilot relief valve

Pilot control lever module

Pilot oil filter

Pressure reducing valve

Main implement pumps

Main control valves

Main relief valve

Variable pump backup relief valve

Pilot ON/OFF solenoid valve

Hydraulic tank

Variable pump torque control solenoid valve

Fan drive motor

Fan drive speed control valve

Lift linkage position sensor

Tilt linkage position sensor

Page: 5-43
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

LAB EXERCISES
Lab B: Implement Hydraulic System Tests Worksheet 1

SENR1367 Following the procedures in the 992G Wheel Loader Hydraulic Systems
Testing and Adjusting Module (Form SENR1367), perform the following
tests:

1. Page 43 1. Operational Checks

2. Page 44 2. Release of Pressure in Implement Hydraulic System

3. Page 45 3. Fixed Displacement Pump Test

4. Page 46 4. Variable Displacement Pump Test

5. Pilot System 5. Pilot System Pressure Test

- Page 55 - Pilot Relief Valve Adjustment
- Page 56 - Pilot Pressure Supply with Engine OFF
- Page 56 - Pilot Control Valve Chamber Pressure Check

6. Main System 6. Main System Pressure Tests

- Page 58 - Fixed Displacement Pump Main Relief Valve Pressure Test
- Page 61 - Left Valve Dump Line Relief Valve Test
- Page 63 - Left Valve Tilt Back Line Relief Valve Test
- Page 65 - Left Valve Raise Line Relief Valve Test
- Page 68 - Left Valve Lower Line Relief Valve Test
- Page 70 - Variable Displacement Pump Cutoff Valve Pressure Test
- Page 72, 89 - Torque Convertor Stall and Double Stall Test
- Page 73 - Variable Displacement Pump Backup Relief Valve Pressure Test
- Page 77 - Right Valve Dump Line Relief Valve Test
- Page 91 - Fan Drive Pump Cutoff Pressure Test
- Page 92 - Fan Drive Pump Margin Pressure Test

Page: 5-44
 992G WHEEL LOADER
CHAPTER : IMPLEMENT SYSTEM

LAB EXERCISES
Lab B: Implement Hydraulic System Tests Worksheet
PILOT SYSTEM PRESSURE TEST
Pilot Relief Pilot Pressure Engine Pilot Control Valve
Valve OFF Chamber Pressure
Specifications

Machine Pressure

FIXED DISPLACEMENT PUMP

Main Relief Valve Case Drain Flow

Specifications
Machine Pressure

LEFT VALVE GROUP

Dump Line Relief Valve Tilt Back Line Relief Valve
Specifications
Machine Pressure

Raise Line Relief Valve Lower Line Relief Valve

Specifications
Machine Pressure

VARIABLE DISPLACEMENT PUMP

Cutoff Valve Back up Relief Valve

Specifications
Machine Pressure

RIGHT VALVE GROUP TORQUE CONVERTOR

Dump Line Relief Valve Stall Double Stall

Specifications
Machine Pressure

Page: 5-45